SYSTEM, METHOD AND APPARATUS FOR SERVICING SUPPORT POLES

Abstract

Methods of reinforcing a functional component, which may include a support pole or an well casing. The methods include excavating a treatment section around the perimeter of the functional component. The methods may further comprise compacting a fill material up to a fill elevation. The methods further comprise casting a mortar mixture, including with UHPC up to an upper elevation above the ground surface. A forming structure may be implemented comprising a length that corresponds to the intended length of the UHPC pour. Another embodiment of the methods comprises installing a sealant component substantially around the perimeter of the functional component. The sealant component is structured to reciprocally move with the functional component during expansion and contraction thereof.

Claims

1. An annulus excavation tool, comprising: a cylindrical sidewall dimensioned to surround an functional component; a jetting manifold configured to receive a pressurized fluid source; a plurality of fluid jets disposed in a spaced apart relation to one another, each one of the plurality of fluid jets disposed in fluid communication with the jetting manifold and oriented to eject the pressurized fluid source in a downward direction adjacent to the functional component; a vacuum/tremie manifold disposed in fluid communication with a vacuum source; a plurality of vacuum/tremie ports, each one disposed in communication with the vacuum/tremie manifold; each one of the plurality of vacuum/tremie ports disposed in a spaced apart relation to one another on an inside of the cylindrical sidewall; and each one of the plurality of vacuum/tremie ports oriented to remove a material surrounding the functional component.

2. The annulus excavation tool as recited in claim 1 wherein the functional component comprises a support pole.

3. The annulus excavation tool as recited in claim 1 wherein the functional component comprises a well casing.

4. A method of reinforcing a functional component installed in the ground, the method comprising: excavating a treatment section substantially around a perimeter of the functional component; the treatment section comprising a predetermined thickness, introducing a fill material on the treatment section from a bottom elevation to a fill elevation, compacting the fill material, and placing a mortar mixture comprising UHPC at least on a portion of the treatment section.

5. The method as recited in claim 4 wherein the predetermined thickness comprises at least 4 inches

6. The method as recited in claim 4 wherein placing a mortar mixture at least on a portion of the treatment section comprises placing a mortar mixture substantially between the fill elevation and an upper elevation.

7. The method as recited in claim 4 wherein the bottom elevation is at least 5 feet below grade elevation.

8. The method as recited in claim 4 wherein the fill elevation is between 1 feet and 3 feet below grade elevation.

9. The method as recited in claim 4 wherein the upper elevation is between 1 feet and 3 feet above grade elevation.

10. The method as recited in claim 4 further comprising installing a forming structure around the functional component.

11. The method as recited in claim 10 wherein the forming structure comprises a length that is at least equal to a length of the treatment section.

12. The method as recited in claim 10 wherein the forming structure comprises a sonotube.

13. The method as recited in claim 4 wherein the treatment section comprises a thickness of at least 8 inches.

14. The method as recited in claim 13 further comprising installing a forming structure around the functional component.

15. The method as recited in claim 14 wherein the forming structure extends vertically from at least three feet below grade elevation to at least grade elevation.

16. A method of reinforcing a support pole at a production facility, the method comprising: providing a concrete mixing plant at the production facility, cutting the support pole to a desired length, drying the support pole to an intended moisture content, installing a forming structure substantially around the support pole; the forming structure comprising a length substantially defined as the span between a bottom elevation and an upper elevation, placing a mortar mixture around the support pole substantially along the length of the forming structure, and removing the forming structure from the support pole after a period of time that is sufficient for the mortar mixture to gain a desired strength.

17. The method as recited in claim 16 wherein the mortar mixture comprises UHPC.

18. A method of protecting a functional component, the method comprising: excavating a treatment section substantially defined around a circumference of the functional component; the treatment section comprising a predetermined thickness, placing a forming structure around the functional component, installing a sealant component on at least a portion of the functional component; the sealant component configured conform to the geometry of the functional component during expansion and contraction thereof, installing a retaining structure around a bottom face of the sealant component, and placing a mortar mixture comprising UHPC on the treatment section from a bottom elevation to an upper elevation; the upper elevation being substantially coincident with a top portion of the reinforcement structure.

19. The method as recited in claim 18 further comprising installing a reinforcement structure around a top portion of the reinforcement structure.

20. The method as recited in claim 19 wherein installing the reinforcement structure around a top portion of the functional component comprises installing the reinforcement structure around a top portion of the functional component in a spaced apart relation to the sealant component.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1a is a view of a damaged utility pole utilizing a repair method according to aspects of the invention.

[0031] FIG. 1b is a close up view of a damaged utility pole utilizing the repair method.

[0032] FIG. 2a is aside elevation view of a trailer mounts system for repairing a support pole annulus according to aspects of the invention.

[0033] FIG. 2b is a top plan view of the trailer mounted system for repairing a support pole annulus.

[0034] FIG. 3 is a flow chart of the stages of the support pole repair process.

[0035] FIG. 4 is an image depicting four stages in the support pole repair process.

[0036] FIG. 5 is a top plan view of the annulus tool.

[0037] FIG. 6 is a cross section view of the annulus tool according to the present invention.

[0038] FIG. 7 is a front section view of one embodiment of an encasing annulus according to the present invention disposed on a functional component comprising a support pole.

[0039] FIG. 8 is a front section view of another embodiment of an encasing annulus according to the present invention disposed on a functional component comprising an oil well casing.

[0040] FIG. 9 is a front section view of one embodiment of a reinforcement structure according to the present invention comprising a sealant component and disposed around the perimeter of a functional component.

[0041] FIG. 10 is a front section view of another embodiment of a reinforcement structure according to the present invention comprising a sealant component and disposed around the perimeter of a functional component.

[0042] FIG. 11 is a front section view of even another embodiment of a reinforcement structure according to the present invention comprising a sealant component and disposed around the perimeter of a functional component.

[0043] FIG. 12 is a top section view of yet another embodiment of a reinforcement structure according to the present invention comprising a sealant component and disposed around the perimeter of a functional component.

[0044] FIG. 13 is a front section view of one embodiment of reinforcement structure according to the present invention disposed on a functional component.

[0045] FIG. 14 is a diagrammatic representation of one embodiment of a method according to the present invention for reinforcing a functional component.

[0046] FIG. 15 is a diagrammatic representation of one embodiment of a method according to the present invention for reinforcing a support pole at a production facility.

[0047] FIG. 16 is a diagrammatic representation of one embodiment according to the present invention for protecting a functional component.

[0048] FIG. 17 is a front section view of a further embodiment of an encasing annulus according to the present invention disposed on a functional component comprising.

[0049] FIG. 18 is a cross-sectional view of the embodiment as represented in FIG. 17.

DETAILED DESCRIPTION

[0050] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The Description is not to be take in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

[0051] Broadly, embodiments of the present invention provide a system, method, and apparatus for the prevention and restoration of decayed support timbers that have a base end that is driven into or buried in a ground surface. The support poles may include; utility poles, support pylons for piers, retaining walls, elevated construction, and the like. Additional embodiments of the present invention, provide a system, method and apparatus for the protection and restoration of decayed material around other types of functional components, including not only support poles, but also functional components relating to hydrocarbon extraction. Such functional components may comprise oil and gas well casings, which may also be installed on the ground and may similarly be subject to environmental decay at similar elevations, roughly between +0.5 to 1.5.

[0052] As seen in reference to the non-limiting embodiments shown in FIGS. 1A and 1B, aspects of the present invention include a support pole 10 having a decayed area 12 proximal to a ground surface 14 into which a based end of the support pole 10 is buried. The decayed area 12 of the support pole 10 may be repaired by the application of an encasing annulus 16 surrounding the support pole 10 above and below the ground surface 14. As will be appreciated, the ground surface 14 may be below the surface of a body of water in which the support pole 10 is emplaced. Preferably the encasing annulus 16 is formed of a concrete or a cementitious material.

[0053] Wood decay is present, primarily from +0.5 to 1.5 because moisture and oxygen are typically available at these depths. The types of decay that cause ground line failure to wooden utility poles include: soft rot or exterior rot; core rot; and brown rot. Soft rot is where the outer part of the pole is attacked by decaying organisms present in the soil. Core rot attacks the center of the pole. Although the figures show exterior rot this invention will cure both types of rot because water and oxygen can't infiltrate the pole.

[0054] In the embodiment shown in FIGS. 1A and 1B, the invention when applied to a 40 wooden utility support pole 10 with a bottom end 11 that is embedded in 6 of soil. Wood decay 12 is present, proximal to the ground surface 14, primarily from a range of +0.5 to 1.5 relative to the ground surface 14. These dimensions are representative only, and are indicative of the condition of one of many of the millions of support poles 10 which are in need decay remediation. As will be appreciated with the benefit of the present disclosure, the encasing annulus 16 may be applied as a remedial measure for the restoration of a support pole 10 with decay 12 or the encasing annulus 16 may be applied in an original installation of a support pole 10.

[0055] A system for installation of an encasing annulus 16 to a decayed area 12 of a support pole 10 may be seen in reference to FIGS. 2A and 2B. The system may be mounted on a truck or a trailer 31 that is towed by a tractor vehicle 34 to carry equipment on site and between sites. The system provides a pressurized fluid source, a vacuum source, and a mortar delivery source. As described more fully below, an annulus tool 40 is utilized to direct a jet of a pressurized liquid, such as water, around the periphery of the support pole 10, to facilitate evacuation of the soils around the pole and define a void 36 in a space surrounding the decayed area 12 of the support pole 10. Use of the annulus tool 40 also includes suctioning off the released soils from the void 36 around the support pole 10. Use of the annulus tool 40 also includes injecting a mortar mixture 52 into the void 36 to form the encasing annulus 16.

[0056] With a basic understanding of the system from the foregoing, the system includes a control unit 20 for control of the system and one or more pumps 22. The control unit 20 controls the one or more pumps 22, which may include a pressurized delivery pump 22, a suction pump 22 and, a tremie delivery pump 22. The one or more pumps 22 are in fluid communication with the annulus tool 40 via a conduit 18 for each of the pressurized delivery pump 22, the suction pump 22, and the tremie pump 22.

[0057] The system also includes a storage container 25, preferably at a forward end of the trailer 31. The storage container 24 is utilized to secure the annulus tool 40, associated tools, conduits, connectors, and supplies for operation of the system. An electric generator for power required by the system may also be carried in the storage container 24 or otherwise mounted to the trailer 31.

[0058] A bulk storage 26 is provided for carriage and containment of a quantity of mortar mix, which may be carried in bulk, or in a plurality of bags. The bulk storage 26 may include a hopper to feed a mixing unit 30 to mix the mortar mix with a specified quantity of water, carried in a water reservoir 28 and in fluid communication with the mixing unit 30 and the pump 22. The mixing unit 30 may also received predetermined quantities of other additives, such as plasticizers, colorants, and the like.

[0059] The mixing unit 30 should have a capacity of at least 2 cubic yards, a typical minimum quantity of mortar mix to pump into the void 36 to form the encasing annulus 16. When gunite is locally available, the trailer 31 may not utilize the mixing unit 30 or bulk storage 26. However, a mortar rehandling connection may also provided so that a gunite delivery truck can unload gunite to the trailer 31 and the gunite may be fed to the annulus tool 40 at the design deliver rate via the tremie pump.

[0060] A solid decant unit 32 may be provided for containment and filtration of the backfill materials evacuated by the suction pump 22 to limit undesirable dispersion of the fines and granular materials on the worksite for environmental containment.

[0061] The jetting hoses 18 from the trailer mounted equipment will be hooked up to a jet pipe manifold 44 of the annulus tool 40. A vacuum hose 18 will be connected to a vacuum and tremie manifold 54 of the annulus tool 40.

[0062] A method of using the annulus tool 40 and servicing system is shown in reference to FIGS. 3 and 4. In use, the selected size annulus tool 40 will be assembled around the pole 10 to be repaired. (FIG. 3, STAGE I). By way of non-limiting example, the annulus tool 40 may be formed of 2 sections of a schedule 10, 14 OD steel pipe (or bent steel plate) that will be fixed together with a fastener, such as pin connections, bolts, or screws to join the lugs 45. Alternatively, a band fastener may be applied to the outer circumference of the cylindrical sidewall 43.

[0063] The annulus tool sections 41 may be separated from the support pole 10 with 2 spacers 43 that may be welded to the inside of the arcuate wall segment 43. The spacers 43 may be wide, thick, and 4 long skids on the interior face of the support pole 10 or pile to allow for sliding along a longitudinal length of the support pole 10. The spacers 43 and 4 long and spaced with 4 openings. In the embodiment shown, the spacers 43 divide the annulus tool into 8 sections. Each section created by the spacers 43 may have two jetting nozzles 46 and at least one 1.75 inch pipe for the vacuum/tremie port 56 for removal of dislodged back fill material and decayed wood waste and will be used later for tremieing the liquid mortar 52. The opening may optionally have provisions to receive at least one fiber or steel reinforcing rod 60. In some embodiments, the annulus tool 40 may be provisioned with ore or more underwater cameras 70 at a bottom end of the annulus tool 40 (one on each half) to observe when the bottom of the support pole 10 is clear of decayed material 12.

[0064] As would be understood, the support poles 10 may have a taper on the order of in the 4 length of the annulus tool 40. The spacers may have to have a skid on the surface next to the support pole 10. The tool may have to be loosely fit in the beginning of the descent to allow for that taper.

[0065] When the back fill material is sand or silt the material will have no trouble vacuuming to the surface. Stiff clay may come out initially too large or sticky to go up the 1.5 vacuum pipe. The 1.5 vacuum pipes will be nozzled down to 1.25 at the bottom to prevent marginal size gravel from entering the pipe and forcing them to the bottom. Likewise, larger gravel may have difficulty moving to the surface, and that is an additional reason for the camera 70. The annulus tool 40 may have to be picked up and then re-jet some of the clay or jet the large gravel to the bottom. A vibrator attached to the annulus will enable the large gravel to descent downward. Some of the finer material may be carried up the void and bypass the vacuum on the ground surface 14.

[0066] Disposal of the Waste SoilThe volume of the annulus and the amount of solid soil to be disposed of is on the order of 4.2 cubic feet. With a 10:1 dilution the volume of the solution of soil and water is approximately 315 gallons. When the material is predominately granular it can be disposed of around the base of the mortar collar. When there is a solution of fines in an urban setting, the 315 gallons may be collected to be hauled off site. In a rural setting the solution of fines could probably be diked, or contained on the land.

[0067] Tremie the Mortar-After the cameras 70 clear the annulus at elevation 2.0 the vacuum conduit 18 will then be connected to the tremie pump 22 for delivery of the liquid mortar 52 and the tremie/fill process will begin. With the reinforcing rods 60 in place, the annulus tool 40 is selectively raised by hand or a lifting mechanism, slowly as the void 36 is progressively filled with the mortar grout 52. The system may also include an electric winch may be attached to the support pole 10, if needed, to selectively raise the annulus tool 40 when there is resistance. One or more vibrators may be available to assist in lowering and raising the tool, if needed. The one or more vibrators may also facilitate consolidation and compaction of the liquid mortar mix 52.

[0068] Pouring the Above Ground SegmentThe annulus tool 40 is removed at grade 14 and a Sonotube form 38, fabricated from a reinforced cardboard, plastic, fiberglass, metal, or the like, is inserted to replace the cylindrical shaped annulus tool 40. The pour pf the liquid mortar 52 is then completed to a desired vertical distance above the ground surface 14. The desired vertical distance is typically from 0.0 to +1.0 above the ground surface 14. When servicing pilings 10 in the vicinity of a body of water, the desired vertical distance may be selected based on a high watermark, a high tide level, or other desired clearance to prevent deterioration of the piling 10 by the waters contained in the body of water. In the case of some applications, a composite pole may be used with the mortar poured as high as 14.0 elevation to not only remove the decay but fire proof the pole an achieve a major increase in the strength of the pole.

[0069] As with the subterranean pour, a small vibrator may be provided for compaction of the elevated pour. The above pour should continue immediately after the first pour so the first pour of mortar grout 52 is still wet and a suitable bond is achieved between the subterranean and above ground pours.

[0070] The historical method of installing wood utility poles 10 was to drill a hole that is at least 8 larger in diameter than the butt end of the pole 10. Then the pole 10 is plumbed and centered in the hole for its desired vertical orientation. If the excavated material is suitable then the surrounding hole is back filled with the excavated material in 6 compacted lifts to get the lateral support necessary to support the pole 10. Suitable back fill materials exclude bedrock, boulders, soft clay or silt, and poorly graded sand and any material when there is water in the hole. If the backfill material was unsuitable, the installation would used a select fill of well graded granular material of pea gravel or crushed limestone, typically to a minus 5 sieve. Accordingly, after assembly of the annulus tool 40 to the support pole 10, the 2 annulus in this invention will be jetted down n the backfill material that was recompacted in the initial installation of the support pole 10 in a 4 soil annulus and the jetting should be relatively easy and can be done in any geological site condition.

[0071] Dislodging the backfill materialThe basic design shows 2 jets with plastic pipe per section or a spacing of every 2.5. The jets may be low pressure in environments with a sand back fill material and a high pressure in stiff clay back fill material. The jet piping may be PVC in low pressure and copper or other metallic material in high pressure conditions. The plurality of jets 48 may have a rotating or a revolving conical head of about 30 degrees and be similar to jets used in sinking sheet piling. The jets 48 may be oriented on a 10-degree angle toward the support pole 10. A collection manifold may be formed of 1.5 plastic pipe at the top of the annulus tool 40 on each half section and high-pressure hoses 18 connected to each of the manifolds (FIG. 5). The hoses will join in a Y connection and go to the pump 22.

[0072] Vacuuming the SoilThe vacuum/tremie ports 56 will also collect with a manifold 52 at the top of each half section and suction hoses 18 connect to them also. The suction hoses 18 may join in a Y connection and go to the vacuum pump 22.

[0073] The annulus tool 40 according to aspects of the invention is shown in reference to FIGS. 5 and 6. The annulus tool 40 may include at least two segments 41, 41 that are connectable to surround the circumference of the support pole 10 to be repaired. The annulus tool 40 may have a support frame defined by an arcuate wall segment 43 having connecting lugs 45 to retain the annulus tool 40 around the circumference of the support pole 10. An annular support plate 49 extends from an outer surface of the arcuate wall segment 43 and supports a jetting manifold 42. When the segments 41 and 41 are joined, the arcuate wall segments 43 define a cylindrical wall surrounding an outer circumference of the support pole 10. A top plate 53 is attached to a tope end of the arcuate wall segment and supports a vacuum/tremie manifold 45.

[0074] The jetting manifold 42 is configured to communicate the pressurized fluid, such as water, via a plurality of spaced apart fluid jets 46 that extend downwardly from an interior of the arcuate wall segment and are oriented to eject the pressurized fluid downward towards the ground surface 14 surrounding the support pole 10. The jetting manifold 42 may also include a plurality of secondary fluid jets 48 that are configured to direct the pressurized fluid towards the decay region 12 of the support pole 10 to hydraulically remove the decayed wood 12 from the support pole 10 to be repaired.

[0075] The vacuum/tremie manifold 52 has a plurality of spaced apart tubes that are selectively coupled between a vacuum source and a source of mortar 52. When coupled to the suction pump 22, a plurality of vacuum/tremie ports 56 are oriented to extract the hydraulic fluid and the fluidized fill material to evacuate the void 36 about the support pole 10. When coupled to a mortar source, the vacuum/tremie manifold 52 delivers a slurry of mortar mix 52 within the evacuated void 36 surrounding the support pole 10.

[0076] The annulus tool 40 may also carry a plurality of spacers 47 interposed between the plurality of fluid jets 46 and the plurality of vacuum/tremie ports 56. The spacers 47 are configured to carry reinforcing rods 60, such as rebar, which may be deposited in the mortar 52 as the annulus tool 40 is withdrawn from the void 36.

[0077] Since the support poles 10 may have differing outer diameters, different annulus tool 40s may be required. As such, an inner diameter of the annulus tool 40 is dimensioned to correspond to that of a selected support pole diameter, or range of diameters. The support poles 10 to be remediated will have been surveyed so that the size of support pole 10 is known and an estimate of the decay amount 12 and location will be available.

[0078] Mortar Gout DesignThe mortar mix 52 fill provides the strength and protective barrier to correct for the structural deficiencies from prior decay and to simultaneously seal the pole so water and oxygen can no longer infiltrate to the pole in the vulnerable area from elevation +0.5 to 1.5.

[0079] There have been recent developments in Ultra-High Performance Concrete (UHPC) that have substantially raised tensile and flexural strengths which will be useful in developing the bending strength required. Cement mortars hat have high ultimate strain values resulting in first crack and strain values being much lower than normal concrete are also desirable. The UHPC grouts have attained bending strengths in the range of 3,000 to 3500 psi and this enables a repair that result in a support pole/pile 10 that is stronger than the original. At these levels re-bars 60 may not be necessary. These new grouts also are very dense with minimum voids resulting in total resistance to not only insects but any chemicals in the soil or water that would normally attack concrete. UHPC may be used in connection with various embodiments of the annulus tool, systems, and methods described herein.

[0080] To prevent air and water from infiltrating to the support pole 10 in the region where the decay 12 occurs (elevation +0.5 to 1.5) an encasing annulus 52 of fiber reinforced grout 52 is poured around the once decayed area 12 and at least 0.5 feet above and below the decayed area 12. The mortar mix 52 fills the void in the area evacuated by the annulus tool 40 suctioning as well as the voids in the support pole 12 that are introduced with the removal of the decayed wood 12 from the support pole 10.

[0081] A desirable mortar mix 52 may have the following characteristics to form an encasing annulus 16 a thickness of about 2.

[0082] Either steel or polypropylene fibers-2% by volume;

[0083] Durability and toughness;

[0084] High ultimate strain value of over 5% so first crack and first strain values are significantly lower than normal concrete. This results in much less cracking at the ultimate load and results in the material being very ductile;

[0085] Shrinkage is low with additives;

[0086] Low permeability and high ductility;

[0087] Mix than can be pumped thru the conduit 18 and suction/tremie manifold 52 and 1.75 pipe.

[0088] A bonding agent, if required; and

[0089] A plasticizer for workability and pumping.

[0090] The selected mix chosen should result in an impervious barrier to prevent water and air infiltration from getting to the pole 10. The grout 52 may be reinforced with a fiber reinforcing bar 60 embedded in the encasing annulus 16. The reinforcing bars 60 may be held in place by 1 steel loops (U shaped brackets) welded to the annulus tool 40 and fixed at the top to the support pole 10. As the annulus tool 40 is withdrawn, the one or more reinforcing bars 60 stay in place. The upper ends of the one or more reinforcing bars 60 may be stapled to the support pole 10 to retain them in place. The reinforcing bars 60 may be metallic rebar or a fiber reinforcing bar.

[0091] With reference now to at least FIGS. 5-8 and, the annulus tool 40 according to the present invention may be used in connection with treating a functional component, which is shown as 10. That is, the annulus tool 40 according to the present invention may be used in connection with a support pole, and also with well casings as may be used in hydrocarbon extraction procedures. Accordingly, the annulus tool may comprise a sidewall dimensioned to surround the functional component 10. The annulus tool 40 may also comprise a jetting manifold 44 configured to receive a pressurized fluid source and a plurality of fluid jets 48 disposed in a spaced apart relation to one another. Each of the plurality of fluid jets 48 may be communicably disposed with the jetting manifold 44 and oriented to eject the pressurized fluid source in a downward direction adjacent to the functional component 10. The annulus tool 40 may also be provided with a vacuum/tremie manifold 54 disposed in fluid communication with a vacuum source and a plurality. Each one of a plurality of vacuum/tremie ports 56 may be communicably disposed with the vacuum/tremie manifold 54 and in a spaced apart relation to one another on an inside of the cylindrical sidewall 43. Furthermore, each one of the plurality of vacuum/tremie ports 56 may be oriented to remove a material surrounding the functional component 10.

[0092] With reference to FIGS. 13-14, the present invention comprises a method 300 of reinforcing a functional component 210 installed in the ground. As shown in FIG. 13, a treatment section 220 may be excavated substantially around the perimeter of a functional component 210, which may be a support pole or another structure for hydrocarbon extraction, e.g., a well-head casing. Examples of support poles may include utility poles, support pylons for piers, retaining walls, elevated construction structures, etc. The existing material that needs to be removed may be dislodged in accordance with the methods described herein. Accordingly, the treatment section 220 may comprise a length 222 and a thickness 224. The length 222 may be substantially defined as the distance between grade elevation, or 0 elevation a bottom elevation 260. For example, the bottom elevation 260 may be about 10.0 to about 4.0. As used herein, negative elevations represent a value of an elevation below grade level, and positive elevations represent a value of an elevation above grade level. In at least one embodiment, the bottom elevation 260 may be about 6.0. It is within the scope of the present invention that the diameter of the treatment section 220 should be at least larger than the diameter of the functional component 210 to be treated. In at least one embodiment, the diameter of the treatment section 220 should be about 16 to about 20. Thus, depending on the thickness of the underlying functional component, the thickness 224 of the treatment section 220 be at least about 4 inches for 12 diameter poles. However, the thickness 224 may be larger or smaller depending on the specific application. In at least one embodiment, the thickness 224 may be about 8 inches.

[0093] As is shown FIG. 13, a fill material 230 may be placed around at least a portion of the treatment section 220. Suitable fill materials may include, without limitation, fill material substantially without any large gravel. Accordingly, the fill material 230 may be placed from a bottom elevation 260 to a fill elevation 250. Thereafter, the fill material 230 may be compacted, for example, with a vibrator. Accordingly, it is within the scope of the present invention that the elevation of an already placed fill material 230 may be lower after compaction. Thus, additional fill material 230 may be added and/or further compacted until the elevation reaches the fill elevation 250. The fill elevation 250 may generally be about 3.0 to about 1.0. In at least one embodiment, the fill elevation 250 may be about 2.0. Thereafter, a mortar mixture may be placed above the fill elevation and up to a desired elevation above grade, which is herein referred to as an upper elevation 270. The upper elevation 270 may generally be +1/2 to about +3. In at least one embodiment, the upper elevation 270 may be about +1. In an alternative embodiment, which will be described later, the upper elevation may extend up to +14, or even higher. Thus, it is contemplated that the mortar mixture may be placed substantially on the portion of the treatment section 220 not comprising the fill material 230. Furthermore, the mortar mixture will substantially define a reinforcement component 216 that will surround the functional component 210. The mortar mixture may comprise UHPC. Here, select fill may be used outside the UHPC and may be vibrated to at least partially increase the structural integrity of the reinforcement component 216 and/or the material surrounding it. In order to place the mortar mixture, a forming structure may be placed around the functional component 210. The forming structure may comprise a length that is at least substantially equivalent to the length 222 of the treatment section 220. But, the length of the forming structure may be longer, and may extend above grade elevation, at least to the upper elevation 270. In at least one embodiment, the forming structure may comprise a sonotube or a reusable steel form. Furthermore, in at least one embodiment an annulus tool 40 as described herein may be implemented to cast the reinforcement component 216. However, this is not strictly necessary, as implementing vacuuming, jetting, and/or a tremie are not strictly required, as the method 300 may be achieved with tools and/or processes, including for excavation and/or placing the mortar mixture.

[0094] With reference to FIG. 14, the method 300 according to the present invention comprises excavating a treatment section around a functional component, which is shown at 310. The method 300 further comprises introducing a fill material 320 at least on a portion of the treatment section, and compacting the fill material 330. The method 300 may further comprise installing a forming structure around the functional component, which is shown at 340. The method 300 further comprises placing a mortar mixture around the functional component 350.

[0095] As shown in FIG. 15, additional features of the present invention comprise providing a method 400 for reinforcing a support pole at a production facility. In certain situations, it may be advantageous to manufacture a support pole that is already reinforced and can be installed on a desired location or site, which may not be within proximity to the production facility. Accordingly, the method 400 comprises providing a concrete mixing plant at a production facility 410. Although, a mixing plant may be provided incorporating some of the operative features described herein, e.g., mixing unit, at a minimum the mixing plant should be provided with sufficient capabilities to produce a mortar mixture. In at least one embodiment, the mixing plant should comprise sufficient capabilities to produce a mortar mixture comprising UHPC. Thus, at the production facility, logs may be cut into an intended support pole length 420. For example, the lengths of the support poles may vary and may be anywhere from about 20 to about 50. Further, and also by way of example, the diameter of the support poles may vary from about 6.7 for 20 long support poles to about 13.4 for 50 long support poles.

[0096] Thereafter, the support poles that are cut may be dried to an intended moisture content. Thus, support poles may be air dried or may be kiln dried to remove free water, i.e., non-shrinkage water. By way of illustration, the intended moisture content after the support poles are died may be about 20% to about 30%. In a preferred embodiment, an intended moisture content of the support poles after drying is about 20%. In at least one embodiment, the support poles may be sent to a mill where they may be dried and/or chemically treated, if desired. In that case, installation of UHPC may occur after the support poles are chemically treated.

[0097] Thereafter, a forming structure may be installed around the support pole 440. The forming structure may be configured and dimensioned to correspond to the length and/or geometry of the support pole. That is the forming structure may be installed around an intended portion of the support pole where reinforcement structure will be cast. For example, the forming structure may comprise a length spanning from an intended bottom elevation to an intended upper elevation of the support pole once it is installed. Accordingly, the method 400 further comprises placing a mortar mixture around the support pole substantially along the length of the forming structure 450. The method 400 further comprises removing the forming structure form the support pole after a sufficient period of time for the mortar mixture to gain a minimum acceptable strength 460. In general, the forming structures may be removed after a period of time sufficient for the compressive strength of the mortar mixture is least about 40% of the intended compressive strength. For example, 40% of the intended compressive strength may be reached in about 1 day. Furthermore, the intended compressive strength may be about 18,000 psi to about 22,000 psi. In at least one embodiment, the intended compressive strength may be about 20,000 psi. Thereafter, a hole configured to accommodate an intended support pole size with a reinforcement component, may be excavated on the intended installation site. For example, a 24 hole may be excavated and select fill may be introduced and/or compacted as needed. Compaction may be achieved with a vibrator.

[0098] With reference now to FIGS. 9-12 and 16, even additional features of the present invention comprise providing a method 500 of protecting a functional component 110 as defined herein with reinforcement component 120 comprising a sealant component 130. In some situations, it may be advantageous to provide for a sealant component 130 that may not only provide an enclosure to the reinforcement component 120 around an intended area. An added benefit of the sealant component 130 is that it would at least partially reduce the need to apply a chemical treatment to the functional component 110 to protect it from environmental conditions. Often times, such chemical treatments may be harmful not only to the environment, but may also pose a health risk. Thus, a reinforcement component 120 may be provided with a sealant component 130 around an intended area where the functional component 110 would otherwise need chemical treatment. For example, such an intended area of the functional component 110 may be an area below the ground surface that is susceptible to decay and/or moisture accumulation, and which will be covered or otherwise encapsulated by the length 136 of the sealant component 130. Accordingly, a reinforcement component 120 with such a sealant component 130 would provide various advantages. Furthermore, the sealant component 130 may be configured to expand and/or contract according to expansion and contraction cycles of the underlying functional component 110, which may comprise wood, concrete, steel, other related materials, and/or combinations thereof. The reinforcement component 120 with the sealant component 130 may be provided on an already-installed functional component 110. Alternatively, the reinforcement component 120 with the sealant component 130 may be installed on a wood support pole that is cut and prepared at a production facility as described herein.

[0099] As shown in FIG. 9, the sealant component 130 may be installed on the functional component 110 substantially around a planned top section of the reinforcement component 120. The sealant component 130 may comprise an expandable material including, but not limited to a silicone rubber strip. For example, the sealant component 130 may comprise a 1 HS silicon rubber strip. Also as an example, the sealant component 130 may comprise a thunder rubber silicone, including THSIL 650, which may have a life expectancy of up to twenty years. However, other sealant component 130 materials are also within the scope of the present invention. Also, an adhesive, including a high strength adhesive, may be applied to the functional component 110 where the sealant component 130 will be installed. Furthermore, the sealant component 130 may be installed to the functional component 110 with nails or staples, although other connection mechanisms may also be used. As a further example, the sealant component 130 may be installed to the functional component 110 with stainless steel nails or staples roughly every 6 inches. Accordingly, it is contemplated that once the sealant component 130 is installed, it should move along with the functional component 110 as it expands and/or contracts, for example, during temperature changes. By way of example, the illustrative embodiment of FIG. 11 shows a shrinkage distance 160, in the horizontal direction, of the functional component 110. Accordingly, the width of the pole w may be reduced b this shrinkage distance 160, resulting in a smaller width w for example during lower temperatures of a shrinkage cycle.

[0100] As is also shown on the illustrative embodiment of FIG. 9, a conforming component 134 may be provided at a bottom face of the sealant component 130. The conforming component 134 is primarily intended to at least partially reduce water migration between the sealant component and the reinforcement component 120 and towards the functional component 110. The conforming component 134 may comprise a material that at least partially reduces friction during movement, for example during contraction and/or expansion cycles. In at least one embodiment, the conforming component 134 may comprise a Mastic material. As shown in FIG. 11, even though a gap, i.e., 160, may be created during contraction or shrinkage cycles, and that water may accumulate in this gap and even freeze, it is contemplated that the sealant component 130 may be provided with a strength that may allow it to conform to such dimensional and/or stress constraints. For example, the sealant component 130 may comprise a strength of 19 psi, facilitating it to conform to such expansions as may be associated with freezing of retained water. As an added component, an optional secondary seal 139 may be disposed above the sealant component 130 adjacent to the functional component 110. This optional secondary seal 139 may comprise a soft silicone caulk material, that may at least partially reduce water migration between the sealant component 130 and the functional component 110.

[0101] As is also shown in the illustrative embodiments of FIG. 10-12, the reinforcement component 120 may be provided with a structural steel bar(s) 140 around the top outside corner for stability. As an example, the structural steel bar 140 may comprise a #2 structural steel (SS) bar. However, a structural steel bar 140 comprising another size or more than two structural steel bars 140 may be provided according to the intended application. The structural steel bars 140 may be provided with a grade 75 structural steel. However, other grades of steel are also contemplated according to the specific case. As shown in FIGS. 10-11, the structural steel bar(s) 140 may be disposed in a spaced apart relation to the sealant component 130. The structural steel bar(s) 140 may also be disposed below the top surface 122 of the reinforcement component 120. Accordingly, the spaced apart relation to the sealant component 130 and a minimum separation from the top surface 122 of the reinforcement component 120 at least partially provides for a sufficient coverage for the structural steel bar(s) 140 to provide reinforcement strength.

[0102] The method 500 may comprise excavating a treatment section as defined herein substantially around a circumference of the functional component 510. The method 500 further comprises placing a forming structure 150 around the functional component 520. The forming structure 150 may comprise a horizontal segment 154 as well as a vertical segment 152. Alternatively, the forming structure may be provided with only a vertical segment 152. The method 500 further comprises installing a sealant component 130 at least on a portion of the functional component 110, which is shown at 530. As is perhaps best shown in FIG. 9, the sealant component 130 may comprise a length 136, which may correspond to an intended protection area from decay.

[0103] The method 500 further comprises installing a retaining structure 134 at around a bottom face of the sealant component 130, which is indicated at 540. The method 500 further comprises placing a mortar mixture comprising UHPC on the treatment section from a bottom elevation to an upper elevation, which is shown at 550. The upper elevation may be substantially coincident with a top portion of the reinforcement structure 216. Although not necessarily required, but for added stability and structural integrity, as is shown in FIG. 9, a reinforcement structure 140 may be disposed around a top portion of the functional component 110. The reinforcement structure 140 may be disposed in a spaced apart relation to the sealant component 130.

[0104] With reference now to FIGS. 17-18, additional features of the present invention comprise providing an encasing annulus that extends to an extended upper elevation. For instance, sometimes it may be necessary to reinforce a functional component 10 along a substantial portion of its height, and not only at an area susceptible to decay, e.g., near and/or below ground elevation. It may also be desirable to supply a functional component 10 that has a reinforcement component 16 up to an extended upper elevation as this would provide extended coverage that may protect the functional component 10 against fire. This extended protection may be of relevance, for example, in connection with functional components 10 as may be used in connection with telecommunication applications, i.e., poles used for 4G or 5G networks. Thus, as is seen in FIG. 17, a functional component 10 may be reinforced with reinforcement component 16 that extends to an upper elevation of about +14.0. However, upper elevations of the reinforcement component 16 of up to about +20.0, or even higher, are within the scope of the present invention. By way of illustration, a reinforcement component 16 that extends to an upper elevation of +14.0 may result a functional component, e.g., a support pole, that is about 1.84 times as strong as a functional component without such a reinforcement component 16.

[0105] The reinforcement component 16 may comprise a mortar mixture, including with UHPC. Generally, various methods described herein may be implemented up to ground elevation 0.0, i.e., excavation of treatment section, introducing and/or compacting a fill material, implementing an annulus too, etc. A forming structure may be placed from ground elevation up to an intended upper elevation to case the mortar mixture. In at least one embodiment, a 1/16 thick forming structure comprising steel may be installed around the functional component 10 to cast the reinforcement component up to the desired extended height or intended upper elevation. Installation of the forming structure may be accomplished by implementing a crane system that may allow access to such elevations. Suitable alignment mechanisms may be implemented in order to enable and/or maintain a proper alignment of the forming structures around the functional structure 10 along its height. Such alignment mechanism may include, without limitation a temporary alignment ring.

[0106] In an even further embodiment of the present invention, ground-penetrating radar (GPR) capabilities may be implemented to ascertain the approximate level of decay of a functional structure. This is primarily intended to ascertain a level of decay in functional structures comprising wood, i.e., support poles, but is not necessarily limiting as it may be implemented with other types of functional structures. Thus, there are some ways in which an existing support pole may be tested to ascertain whether it has decayed to the point where it needs treatment, i.e., a reinforcing structure, or another remedial solution, which may involve replacement. Traditionally, such testing has been accomplished by boring into the support pole to determine its moisture content long a profile of the bore. Although this technique does not involve excavating the surrounding material, it is not ideal as the boring creates an opening that often times is susceptible to air and/or water intrusion, which may independently contribute to the decay of the support pole. Such air and/or water intrusion may contribute to the decay of a support pole notwithstanding the fact that the area of the bore may filled, plugged, or otherwise occupied with another material. Other methods of testing for decay include excavating a section around the support pole in order to attempt to identify decay areas. This method is also not ideal as it involves an added expense and time associated with the excavation process. Accordingly, GPR is an attractive solution to ascertain the level of content of a support pole as it eliminates the need for boring and/or excavating. GPR capabilities may be implemented to emit radio waves within a support pole to detect areas where there is a difference in moisture content. Accordingly, GPR capabilities may be used to ascertain areas within a support pole which have a higher moisture content being indicative of potential decay. Accordingly, it is contemplated that boring and/or excavating will not be required if GPR capabilities are implemented. After a potential decay area is identified, further testing may be conducted, or one or more of the methods described herein may be implemented to reinforce the functional structure.

Application of the Invention

[0107] Utilities Mounted Vertically on the Support PoleFor grounding cables mounted to the support pole 10, simply unstaple and move out of the way for the repair and then restaple to secure the cable to the support pole 10. The grounding rod is normally of out of the way. For TV and Telephone wires, typically they are only buried about 12 deep so they be unstapled and moved out of the way for the repair. After completion, the cables may be reconnected.

[0108] Power Cables-They are typically either 18 or 24 in depth and may have a plastic or metal enclosure on the pole If they are enclosed or if there are more than one, the pole is probably not economical for utilization of the invention. Most of the occurrence of power liens on the pole 10 vertically occur when servicing an underground residential power supply and usually in urban areas.

[0109] Plastic Tool DesignThe tool when constructed of steel weighs 200 pounds in total or 100 pounds per half. A tool made of high strength plastic may be provided to reduce the weight in the field (25 pounds/half) and to cut costs. The plastic tool may be cast as one unit with a plastic hinge.

[0110] Structural Pilesthere are bout 50 million wooden piles in the USA. They are located as follows:

[0111] Projects where the pile supports an upper structure and the annulus can be mounted with no concrete to be removed. Another example are crawl spaces. These projects would be performed with the procedures just like a normal pole repair project.

[0112] Projects where the pile is supporting and is embedded in concrete slabs or concrete pile caps. The concrete has to be removed to repair the pile and then it can be repaired like a normal pole project. The piles embedded in pile caps will probably be replaced and not repaired.

[0113] Marine Projects with a shallow water pile. Marine borers in the top 2 of mud require jetting the annulus into the mud and then sealing the entire pile with grout up to the surface. This will structurally repair the decay at the tidal splash zone and prevent any future decay along the pile. Depending on the depth of water and tide range, the annulus will have to be longer than in a dry environment. The annulus will operate inside a taped and banded jacket or sonotube for 12 hours while the mortar sets up. The truck/plant may be on a barge or on top of the pier.

[0114] Marine Projects in deep waterin large ship wharfs (like 40 deep) where there is marine bore damage in the mud line and gibbles type insect damage in the tidal splash zone it may be economical to repair the pile in 2 steps. First mount the pile with the annulus system and lower it down into the mud line. Proceed with the standard jetting and Tremie method to a depth of 2 in the mud. Then grout the mud line and then raise the annulus out of the mud until it is in the dial splash zone. The annulus would now need a form outside and below the annulus to contain the UHPC mortar. This form could be a plastic removable jacket that would be lowered into position at low tide. The annulus tool would then pump mortar as it was raised thru the jacket. The jacket would stay in place for 12 hours and then be recovered. Both high risk areas for marine bore and insect damage are now protected from future damage and the pile is returned to full strength.

[0115] Rail Road Trestles and BridgesThere are a lot of wood pile structures on rail road rights of way. Some piles 10 are on dry land and some over shallow bodies of water.

[0116] Repair Leaning Poles-Many utility poles are leaning due to high sustained winds or ground line decay damage or both together. These leaning poles are prevalent in coastal areas. The procedure to return this pole to full capacity is as follows:

[0117] Drill the pole 10 to determine the amount of decay 12;

[0118] Attach a winch from tractor to a point high on the pole 10;

[0119] Loosen or hand auger the soil on the pull side of the pole 10;

[0120] Straighten the pole 10 with the winch;

[0121] Jet and pour annulus 3.0 elvv. Use the method in this invention; and

[0122] Substitute a concrete ballast rock for the tractor to free it up and leave that tension on overnight.

[0123] New Pole ApplicationThis system may be also be applied to new piles right after they are installed. Simply jet the annulus tool down a half foot below the anticipated future damage area (2.0) and fill that annulus with the fiber reinforced grout. This can be done for a fraction of the cost of the damaged poles that need to be repaired. This would result in a stronger composite pile with no future decay issues.

[0124] Precasting the Mortar Annulus-New PoleThe 2 mortar annulus 16 may be precast in a factor on the new wood pole and the composite structure installed in a larger hole.

[0125] The present invention, including the annulus excavation tool, system, and method, may be generally applied to a functional component, which is labeled as 10 in FIGS. 7-8, 110 in FIGS. 9-12, and FIG. 210 in FIG. 13. The functional component may comprise a support pole 10, for example as shown in FIG. 7. The functional component may also be a component that is used in connection with hydrocarbon extraction procedures, including an oil well casing, for example, as shown at least in FIG. 8. In such cases and depending on site conditions, it may be necessary to provide additional support to an existing oil well.

[0126] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.